Cushion pile fabric and method



March 1, 1955 F. w. E. HOESELBARTH 2,702,933

CUSHION PILE FABRIC AND METHOD Filed Oct. 23, 1952 v 6 Sheets-Sheet l ATTORNEYS.

March 1,- 1955 F. w. E. HOESELBARTH 2,702,933

CUSHION PILE FABRIC AND METHOD Filed Oct. 23, 1952 6 Sheets-Sheet 2 ATTORNEYS March 1, 1955 F. w. E. HOESELBARTH CUSHION PILE FABRIC AND METHOD 6 Sheets-Sheet 3 Filed Oct. 25, 1952 O E T N mm w W n a March 1, 1955 F. w. E. HOESELBARTH 3 CUSHION PILE FABRIC AND METHOD Filed Oct. 23, 1952 6 Sheets-Sheet 4 INVENTOR 7 51.722 144% fiaeseZJaf/Z- ATTORNEYS F. W. E. HOESELBARTH CUSHION FILE FABRIC AND METHOD March 1; 1955 6 Sheets-Sheet 5 Filed Oct. 23, 1952 ORNEYS.

March 1, 1955 F. w. E. HOESELBARTH 2,702,933

CUSHION FILE FABRIC AND METHOD Filed Oct. 23. 1952 6 Sheets-Sheet 6 INVENTOR 731 2222 wfffiaeselzarffi.

Masland & Sons, canine, 1 s., a corporation of Peil'nsylvania Application October 23, 1952, Serial No. 316,368 4 Claims. (G1. 28:80)

The present invention relates to pile fabrics, especially of the character of carpets and rugs. v

A purpose of the invention is to obtain more adequate support of the pile projections 'of a pile fabric by placing wefts at a position above the wefts around which the pile warps are bound, and along the sides of the pile pro ections in supporting relationship;

A further purpose is to provide recesses exteiiding well up into the back of a pile fabric and to place a resilient elastomer cushion material on the back of the fabric and extend it into the recesses for the puipose of better interlocking with the fabric and also giving cushion extensions into the back, increasing resilience and givihg better support for the pile.

A further purpose is to place 'stutfer warp ends in the back of a pile fabric such as a carpet or rug at two different spaced levels; 1 a Y A further purpose is to interpose wefts between two layers of stutter warp ends, and desirably to place wefts also in front of and behind two 'stufier warp ends.

A further purpose is to bind the pile around the Wefts which are interposed between the two layers of stutter warp ends.

A further purpose is to align the wefts at the back of the fabric with corresponding wefts' interposed betweenthe layers of stufie'r warp ends, and to place other correspond ing wefts at the face of the fabric between the aligned pairs of wefts below the same, A a

A further purpose is to manipulate the stu'fler' warp ends by a single stuffer war'p heddle set holding some of the stutter warp ends eyes and others of the stuife'r warp ends in long slots extending below the eyes.

A further purpose is to form an upper, middle and lower shed simultaneously, placing one group of 'stufie'i' warp ends between the upper and middleshe'd' and all other group of stufier warp ends between theirliddle and lower sheds and to insert a wire in the upper shed; and simultaneously insert weftsin' the middle and lower sheds;

Further purposes appear in the specification and in the claims. I V

In the drawings I have chosen to illustrate a few only of the numerous embodiments in which my inveiition appears, selecting the forms shownfromthe standpoints of convenience in illustration, satisfactory operatioh' afld clear demonstration of the principles involved.-

Figures 1 to 6 inclusive'are stepwise longitu l weave diagrams showing the weaving" of a 'pile' fab'ri in accordance with the present invention? Figure 7 is a stepwise weave diagram showing an alternate for the combined steps of Figures 2 and- 3 and of Figures and 6. v

Figures 8 to 10 are stepwise longitudinal weave dia grams showing a further alternate;

Figure 11 is a longitudinal diagram of the completed weave in accordance with my invention, showing both cut and uncut pile.

Figure 12 is a view corresponding to Figure" 11 showing' the weave after a resilient elastomer cushion layer been applied to the back of the fabric; V I

Figures 13' to 16am diagrammatic showings of the respective cams employed, Figure 1 3 showingtheca-i'n foi one pile heddle set, Figure 14 for another pileheddleset; Figure 15 for the stulfer' warpheddle set, and Figilre 1'6- for the binder warp heddle set, used inFig'ures l to 6;

Describing in illustration but not in limitationand' re ferring-to the drawings: a

1 In the production ofpile fabrics,- suchascarptsand gugpex'ggnnw useis how beiiig ma jof synthetic fibers such as rayon; nylo'n, polyvinylidine chloride, and the like for pile yarn, as w ell as cotton. Many ofthese materials are not so resilient as wool; an especially when formed is; h hl l s. 1' hav h d nwm ma n uprrs tg q and to re n tQ, t a P t h de- PI i] I 6 we t th at r by fu i ure, Accordilng'ly some of the carpets produced with summaer as ha e a r e p' id r m rge h c is tPleas- El-rit and do not' giv a pile of attractive appearance after sw a le-w r... is ,1 v..,. It is jlso] evident that as higher piles' areused even with wool; ,thet'eridncy to ben'dor flatten down isincreased, and the ability of the pile to remain upstanding is less pronounced. g g .7

I have discovered that it is possible to support the pile and increase the" tendency of the pile projections to remain hrightahd to restoire themselves to upright position By placing wefts at a position above the wefts behi'rid which the pile warps are bound, and adjacent to the sides of. the pile yarn in the pile projections, Thus the pile is clamped or gripped as in sometypes of brush, and

tends to remain upiig'ht andreturn to upright position, pri'riittiiighiglier piles, Without likelihood of poor wearifig qualities, and permitting use of fibers having little lhesilliler'i5e br' restoring tendency in piles of moderate "ea Errerts have beeri i'nade recentyears to apply cushion materials such as rubber and synthetic rubber, especially in the forth of foa'nhto the back o'f carpets and rugs. It is often diflicult to obtain adequate adherence ofsuch mate'iials on the back. Furthe rrnore, unless relatively thick deposits of resilient elastomer are applied, the resi "in feel imparted is often notnoticeable. I have discovered that this difliculty can be overcome by weaving a fabric having a relatively thick back with channels or recesses rur'ining' along the back, and introducing the rubher at other cushion material into such channels or recesses as Well as spreading it over the back of the fabric, There are thus relatively high ribs of elastomer at the location of each of these channels or recesses, imparting greater resilience due to the greater depth placed in compression tinder the foot of the user. Furthermore the elastomer exten ing into such channels and recesses engages the sides of the wef ts aroundwhich the pile warp extends and extends up into engagement with or immediately below sunnerwefls friontof these binding wefts, so" that the" elastomer n'ot only laterally supports the pile itself-but backs up and provides columnsuppo'rt beneath the stiffener wefts at" the frontof the fabric. 1 v v 1a the d'rawings' I have chosen to illustrate a two ply three shot cushion weave, but it will be evident that the iriv'ritiQh is applicable to otherweaves' employing similar ciples. Likewisel havepreferr'ed to employ a single binder warp; but it will be evident ,of course as well known that a pair of binder warps may be employed as in usual practice where desired. I y

In accordance with the inyention', the stuffer warp is separated or; split into two groups of stuflier warp ends, thus in effect using two stuffe'r warps, although they may, if desired, be drawn from the same beam. p I The invention is applicable, of course, to brussels, Wilton, tapestry and" velvet carpet, and I have chosen to illustrate a weave applied to velvet or tapestry for simplicity in illustration. Pile warp 30 manipulatedby pile warp heddle set 31 is withdrawn from any suitable source, illustrated asbeani 32through tensioning device 33. Pile warp 3 4 manipulated by pile warp'heddle set 35 is suitably withdrawn from the'sam'e beam and the same teusioning device for convenience. Binder warp 36 is withdrawn from beam 37 through tensioning device 38 and manipulat'ed art sans-sass; v

Sti iifer' warp heddle set' 40 suitably has alternating along its wid'tl'rheddle wires 41 having eyes 42 and heddle wires 43 having long slots 44, the tops of which are at a position corresponding to'the eyes 42 and the bottoms of eiiterid beneath the eyes 42 a suflicient distance to place are of the stutfer warps in another shed position as later explained Stufier warp ends 45 withdrawn from i 1 beam 46 through tensioning" device 47 pass through the eyes 42 and stuffer warp ends 48, taken for convenience from the same beam and through the same tensromng device pass through the long slots 44. There is desirably one eye and one long slot per dent, or as often as desired weftwise of the fabric. The wires 41 and 43 are desirably in the same transverse row but are slightly displaced in Figures 1 to 7 so that they can be seen.

It will be evident that the stuifer warp feed (suitably the tensioning device 47) is placed low enough so that when the stuffer warp heddle set 40 is raised half way (Figure 2) the stulfer warp ends in the long slots will be down and those in the eyes will be in mid position.

In the first step of the preferred weave as shown in Figure 1, pile warp and its heddle set 31 are raised half way, pile warp 34 and its heddle set 35 are raised half way, and binder warp 36 and its heddle set 39 are raised half way, while stufier warp ends and 48 are lowered by lowering stutter warp heddle 40, forming a lower shed 50 through which a shuttle passes inserting a shot of Weft 51 which is beaten up by the lay 52.

In the next step as shown in Figure 2, selected pile warp 34 is fully raised by fully raising its heddle set, and stuffer warp heddle set 40 is raised half way, raising stulfer warp ends 45 in the eyes 42 half way to form an upper shed 53. Stuffer warp ends 48 in the long slots 44 rest at the bottom of the long slots and are lowered, pile warp 30 is lowered by lowering its heddle set 31, and binder warp 36 is lowered by lowering its heddle set =39, forming a lower shed 54. A wire 55 which may be cutting, non-cutting, straight, wavy, high, low or intermediate, or may be provided with a non'cutting flag at the end remote from the head, in any alternate sequence or succession of wires, is inserted in the upper shed, and the shuttle inserts a shot of Weft 56 in the lower shed. The lay beats up the wire and the weft.

At the next step, as shown in Figure 3, pile warps 30 and 34 are raised by raising their heddle sets at least half way, stutter warp heddle 40 is raised so that the bottom of the long slot is up at least half way, placing stuffer warp ends 45 in the eyes 42 somewhat higher than stuffer warp ends 48 in the bottom of the long slots 44, and binder warp 36 is lowered by lowering its heddle set 39, forming a lower shed 57 through which a shot of weft 58 is inserted by the shuttle.

This completes the weave, except that since there are two pile warps which are raised alternately in the pile, the steps of Figures 4, 5 and 6 are performed to raise the other pile warp over a wire. Thus Figure 4 corresponds to Figure 1, Figure 5 corresponds to Figure 2 except that pile warp 30 is selected in Figure 5 rather than pile warp 34, and Figure 6 corresponds to Figure 3.

In some cases it is preferable to combine the steps of Figures 2 and 3 and the steps of Figures 5 and 6 and insert two wefts simultaneously as shown in Figure 7 (Figure 7 actually combines Figures 5 and 6). Thus in this form the selected pile warp, in this case 30, is fully raised, while the stuffer warp heddle set 40 is raised to a position in which the upper stufier warp ends 45 form the bottom of an upper shed 60 while the lower stutfer warp ends 48 in the long slot form the bottom of a middle shed 61, the rejected pile warp ends 34 are at the bottom of the middle shed, and the binder warp 36 is in lower position forming the bottom of a lower shed 62. Wire 55 is inserted in the upper shed, weft 56 is inserted in the middle shed by an axminster needle or upper shuttle of a double shuttle loom, and weft 58 is inserted in the lower shed by the shuttle.

The weave of the invention can equally well be produced using separate stutfer warp heddle sets having stutfer warp ends 45 and 48 respectively as shown in Figures 8 to 10. This does not, however, oifer the advantage of combining the heddle sets and thus does not save an extra heddle set as in Figures 1 to 6. Figure 8 corresponds to Figure 1 except that separate heddle sets 40 and 40 are used to manipulate stuffer warp ends 45 and 48 respectively (and eyes are used on both heddle sets, with no long slots), while Figure 9 corresponds similarly to Figure 2, and Figure 10 corresponds similarly to Figure 3.

The resulting weave of the invention as shown in Figure 11 has stutter warps 45 in a layer near the front of the fabric and stuffer warps 48 in a separated layer near the back of the fabric, while wefts 51 are at the front of the fabric, wefts 56 are between the layers of stuifer warps and wefts 58 are at the back of the fabric.

It will be noted that the pile projections, consisting either of uncut pile 63 (dot-and-dash lines) or cut pile '64 (depending upon Whether non-cutting or cutting wires 55 are used) are bound around the wefts 56 between the layers of stutfer warps. The front wefts 51 however are placed forward of these binding wefts 56, and as noted at 65 are in position to support the sides of the pile projections against collapsing.

Also it will be noted that the corresponding binder wefts 56 and back wefts 58 are vertically in line, whereas the face wefts 51 are in staggered relation thereto, the binder warp 36 passing over each face weft 51 and under each back weft 58 and on opposite sides of each binder weft 56.

It will further be evident that voids or recesses 66 from the back of the fabric extend into a position immediately behind each of the supporting face wefts 51.

When a cushion back 67 of resilient elastomer such as rubber or synthetic rubber, suitably in sponge or foam form, is applied to the back, as when the fabric is placed upside down for coating, ribs 68 of elastomer extend up into these recesses 66 in supporting relation to the wefts 51, while a coating layer 69 extends over the back. Thus the ribs 68 give a deep cushion column, which yields under the weight of the foot, but also laterally supports the pile projection above the wefts 56 and backs up the front supporting wefts 51.

The cams which will to advantage be used in the weave of Figures 1 to 6 are shown, Figure 13 showing the cam for control of the heddle set of pile warp 30, Figure 14 showing the cam for control of the heddle set of pile warp 34, Figure 15 showing the cam for control of stuifer warp heddle set 40 and Figure 16 showing the cam for control of the heddle set of binder warp 36.

On each of the cams the six positions have been drawn corresponding to Figures 1 to 6. Each of the pile warp heddle earns 70 in Figure 13 and 71 in Figure 14 at position 72 fully raise the corresponding heddle set, at positions 73 raise the corresponding heddle set half way and at position 74 lower the corresponding heddle set. Likewise in the case of the stuffer warp cam 75 there are positions 76 raising the corresponding stuifer warp ends to positions as shown in Figures 3 and 6, intermediate positions 77 placing the stuifer warp ends on opposite sides of the lower shed as shown in Figures 2 and 5, and lower positions 78 placing all stutfer warp ends down as in Figures 1 and 4.

The binder warp heddle 80 has positions 81 raising the binder warp heddle set half way, and positions 82 lowering the binder warp heddle set. The followers of the cams, as well known in the art, are not shown. It will, of course, be understood that any other suitable cams may be employed where desired.

While the invention is believed to find its widest application in carpets and rugs it will be understood that it will also be applicable where desired to various other pile fabrics.

In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the process and product shown, and I therefore claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A pile fabric comprising pile warp ends, binder warp ends, stuffer warp ends and single wefts interwoven together, the pile warp ends being raised in the pile as pile projections, the stutter warp ends being arranged in two spaced layers, one adjacent the face of the fabric and another adjacent the back of the fabric, single wefts being arranged in three spaced layers, one at the back of the fabric, one between the stuffer warp layers and the other at the face of the fabric, corresponding single wefts in the layer at the back of the fabric and in the layer between the stutfer warp layers being in line, and corresponding single wefts at the front of the fabric being longitudinally displaced with respect to the other single wefts, the binder warp passing around the single wefts at the face of the fabric and under the single wefts at the back of the fabric, and the pile warp ends being bound beneath the single wefts in the layer between the stuifer warp layers, thus forming transversely extending recesses between pairs of single back wefts and between corresponding pairs of single wefts between the stufier warp layers, and a resilient elastomer backing extending over the back of the fabric and extending into the recesses.

2. The method of weaving a pile fabric, using at least one pile warp heddle set, using a stulfer warp heddle set which has mounted thereon eyes at various positions across the fabric and which has mounted thereon long slots extending below the eyes at various positions across the fabric, and having a binder warp heddle set, which comprises raising all pile warp heddle sets and thus raising all pile warp ends, raising the binder Warp heddle set and thus raising all binder warp ends, lowering the stufier warp heddle set and thus lowering all stuffer warp ends, forming a lower shed, inserting a shot of weft in the lower shed and beating up the shot of weft, on the next step fully raising at least one pile warp heddle set, lowering the binder warp heddle set, raising the stulfer warp heddle set half way, thus raising the stutfer warp ends in the eyes and lowering the stutter warp ends in the long slots, and forming upper and lower sheds, inserting a wire in the upper shed, inserting a shot of weft in the lower shed, beating up the wire and the weft, on the next step raising all pile warp heddle sets and thus all pile warp ends, lowering the binder warp heddle set and thus lowering the binder warp ends, raising the stutfer warp heddle set to a position in which the lowermost stutter warp ends are raised at least half way, thus forming a lower shed, inserting a shot of weft in the lower shed and beating up the shot of weft.

3. The method of weaving a pile fabric, using a stuifer warp heddle set which has mounted thereon eyes at various positions across the fabric and which has mounted thereon long slots extending below the eyes at various positions across the fabric, which comprises interweaving pile warp ends, binder warp ends, stuifer warp ends and wefts, and in the interweaving raising pile warp ends in the pile, positioning stuffer warp ends in the back of the fabric at two difierent levels by manipulation of the single stuifer warp heddle set, and interposing single wefts beneath the stulfer warp ends, between the levels of stufier warp ends and above all the stufier warp ends.

4. The method of weaving a pile fabric using a stufier warp heddle set which has eyes mounted thereon at certain lateral positions and long slots extending below the eyes mounted on the stutter warp heddle set at certain lateral positions, which comprises raising all pile warp ends, raising binder warp ends, lowering the stulfer warp heddle set and thus lowering all stutfer warp ends, forming a lower shed, inserting a shot of weft in the lower shed and beating up the shot of weft, on the next step fully raising selected pile warp ends, lowering the binder warp ends, raising the stutfer warp heddle set half way, thus raising the stutfer warp ends in the eyes and lowering the stutter warp ends in the long slots to form upper and lower sheds, lowering any rejected pile warp ends, inserting a wire in the upper shed, inserting a shot of weft in the lower shed, beating up the wire and the weft, on the next step raising all pile warp ends at least half way, lowering the binder warp ends, raising the stuffer warp heddle set to a position in which the lowermost stutfer warp ends are raised at least half way, thus forming a lower shed, inserting a shot of weft in the lower shed, and beating up the shot of weft.

References Cited in the file of this patent UNITED STATES PATENTS 1,849,550 Phoenix Mar. 15, 1932 1,877,679 McCollum Sept. 13, 1932 1,944,534 Underwood Jan. 23, 1934 2,073,227 Shearer Mar. 9, 1937 2,140,134 Kohler Dec. 13, 1938 2,141,152 Kaufman Dec. 20, 1938 2,434,709 Matthews Jan. 20, 1948 2,577,452 Miller Jan. 19, 1951 2,622,998 Stahl Dec. 23, 1952 FOREIGN PATENTS 42,258 France June 21, 1933 (Addition to No. 720,951) 422,054 Great Britain Ian. 3, 1935 

